Stationary/Transportation Heat-to-Power Applications with CN300 ORC Technololgy

© 2014 Concepts ETI, Inc. All rights reserved.

STATIONARY/TRANSPORTATION HEAT-TO-POWER APPLICATIONS WITH CN300 ORC TECHNOLOGY

ASME Turbo Expo 2014 Exhibitor Presentation Stage

CCD Congress Center | Düsseldorf, Germany Keith D. Patch

ORC Product Manager Concepts NREC (CN )

+1 (781) 937- 4616 [email protected]

Tuesday, June 17, 2014, 3:15 PM CET

2 © 2014 Concepts ETI, Inc. All rights reserved.

Copyright Statement

The material in this presentation is covered by various copyrights, including copyright © 2014 by Concepts ETI, Inc. All rights reserved. No part of this publication may be reproduced, transmitted, transcribed, stored in a retrieval system, or translated into any language or computer language, in any form or by any means—electronic, mechanical, magnetic, optical, chemical, manual or otherwise—without prior written permission from Concepts ETI, Inc., 217 Billings Farm Road, White River Jct., Vermont 05001, USA. Portions of this volume may require permissions of individuals associated with organizations other than Concepts ETI, Inc.


Introduce presenter and company Organic Rankine Cycle (ORC) background

and history Heat-to-power applications

Stationary applications Transportation applications

CN300 ORC turbogenerator product/benefits Initial 300 kWe product from Concepts NREC (CN) Low capital cost; minimizes O&M costs Customized aero design to match site requirements Custom designs ensure maximum system efficiency

Presentation Overview


CN is a ≈50 year-old company, with ≈100 employees 72 patents granted, 19 patents pending 39 employees have advanced college

degrees ORC engineering experience: from the

early 1970s to the present time

Keith D. Patch is a 25+ year veteran of the energy field Waste heat recovery, fossil fuels,

biomass, fuel cells, lithium-ion batteries, and nuclear instrumentation

Residential-, commercial-, industrial-, and utility-scale

Introduction

Typical CFD Turbine Analysis Results


Market Opportunity of the Waste Heat Problem

28% of the World’s Total Energy Use Is Wasted but Is

Potentially Recoverable

Productive Utility/ Industrial Energy Use

Can recover 144 GWe of power: US$359B (at US$2,500/kWe)


World geothermal potential is 148 GWe

World biomass potential is 25 GWe

World solar thermal potential is 25 GWe

Natural energy + waste heat markets: 342 GWe or $854B

The World’s Natural Energy Market


Thomas Howard, alcohol/ether engine, 1826 Du Tremblay engine, France, 1850–56 Ether ORC for marine steam engine

Frank W. Ofeldt, U.S. Patent 279,270, 1883 Naphtha ORC engine for marine power

NREC founded, 1956; Concepts ETI, Inc. founded, 1980

1st modern ORC prototype, Harry Zvi Tabor and Lucien Bronicki, 1961

1st commercial ORC sale, Ormat, 1972 CN staff active in ORC development, 1970s–1980s CN CN300 ORC development, began in 2011

ORC Development Timeline


Simple ORC System

Evaporator

HeatTurbine/Generator

ElectricityPump

Condenser

Rejected Heat

An ORC is best suited for making electricity from low-grade heat sources, using an organic fluid to match the fluid’s properties with the temperature of the heat source


Above 50 MWe: steam Rankine cycle is the clear choice For primary power generation For high-temperature waste heat Although a 95 MWe geothermal ORC plant (2013) exists

Below 5 MWe: ORC is the clear choice For primary power generation For low-, medium-, or high-temperature waste heat Eliminate cost of steam boiler plant operators Eliminate cost of water, water treatment system, chemicals,

deaerator, etc.

Why Use the ORC Instead of the Steam Rankine Cycle?


28% of the world’s total energy use is wasted but is potentially recoverable

ORC natural energy market + waste heat equipment market is 342 GWe or $854B

ORC system efficiencies are 10–25% ORC systems are preferred over steam Rankine

cycle systems for most sub-5,000 kWe heat-to-power applications

ORC systems are the only heat-to-power solution for low-temperature applications

Summary of ORC Background and History


Stationary applications Large worldwide installed base Often sized over 100 kWe

• World’s largest ORC = 95 MWe unit Typical uses include:

• Geothermal power • Reciprocating engine bottoming cycle

Transportation applications Representative ORC demonstration units

• Earliest demo: U.S. DOE-funded 36 BHP demo in the 1970s–1980s (photo at right)

• Current DOE SuperTruck program Commercial products not yet available

Heat-to-Power Applications

Patent Pending


Natural sources Geothermal Biomass Solar thermal

Waste heat recovery Waste treatment plants/

incinerators Power generation exhaust Glass and cement industry Oil and gas industry Chemical industry Steel industry Pulp and paper industry

Typical Stationary ORC Applications

Cumulative Worldwide ORC Installations


Truck OEMs must meet stringent fuel economy standards

ORC fuel economy improvement goal of ~6%

Two-stage ORC turbine has better performance, but is too complicated

Down-selected to a single-stage axial turbine

Turbine designed/built/ validated in on-road testing

ORC Design for Heavy Truck Engine – CN/Cummins/U.S. DOE (SuperTruck)

Photo by Sarah Gerrity, Energy Department


CN Has the Solution to Expand the Clean Energy Market

Market Solution Problem 60% of the world’s primary energy is lost as waste heat

CN300–CN5000: reliable, low-

total-cost devices

High capital expense and high maintenance cost of existing waste heat-to-power systems


Commercial Product – CN300

Flow Out

Flow In

Features Hermetically-sealed design Modular turbine cartridge Magnetic bearings (oil-free)

Advantages Simplicity – eliminates all

seals, gears, couplings, lube oil system, and oil contamination

Reduced capital and O&M costs

Reduced footprint Increased reliability Optimized performance Wide working fluid flexibility

Output from 150 to 330 kWe


Competitive Advantages of the CN300


CN300 Specifications Initial member of CN’s ORC Turbine Generator Unit (TGU) product line Designed using CN’s Agile Engineering Design System®

Gross power range 150–330 kWe

TGU speed 20,000 rpm

Turbine inlet temperature range 180–425°F (80–220°C)

Turbine casing inlet pressure rating 700 psig [49 Bar (Absolute)]

Turbine casing outlet pressure rating 200 psig [14 Bar (Absolute)]

Turbine pressure ratio range 2:1–25:1

Working fluid compatibility R112, R113, R114, R134a, R236fa, R245fa

TGU size 42 in. x 24 in. x 34 in. (1.07 m x 0.62 m x 0.87 m) 1200 pounds (544 kg)

Electrical details 400–480 VAC, 3-phase, 50–60 Hz

Agile Engineering Design System is a registered trademark of Concepts ETI, Inc.

Mach Number Contours Through Flow Path

Flow Path


ORC heat-to-power systems are an established clean energy technology

ORC heat-to-power systems can efficiently convert renewable thermal energy and waste heat to electricity

Widespread stationary and transportation ORC applications exist

Recent advancements have improved ORC reliability and virtually eliminated maintenance

The CN300 provides best-in-class first cost, operating and maintenance costs, efficiency, and flexibility for converting heat to ≈300 kWe of electrical power

Summary